Chamfered Gear Contour Measurement Method Using Multi-Camera Concurrent System

Due to massive expansion in automobile industry, research on the gear chamfering angle is becoming more popular. More robust and fast gear measurement methods are being introduced.Gear measurement methods are of two types; Contact and non-contact measurement method. Contact measurement methods of gear include:measurement through, gauges, semi computerized machines and measurement through Coordinate Measurement Machine (CMM). Non-contact measurement methods include:measurement through laser and measurement through machine vision system.Measurement through Coordinate Measurement Machine (CMM) and laser is being widely used in industries for measurement of gear parameters. CMM has high accuracy, but being a contact measurement method, the measurement probe can display wear and tear over the period of time. Measurement through CMM is a slow process and results reproducibilty is very low. As the gears have reflective surfaces hence the measurement through laser requires gear surface and edge preparation i.e. coating with non-reflective paint before measurement, therefor, the process has low accuracy.Measurement through machine vision is non-contact measurement method, therefore, applications of machine vision detection can already be seen in industries and field of robotics. As the current measurement methods for gear chamfering angles are slow and rely on costly machinery. So, this thesis presents gear chamfering angle measurement method by stereovision system.The thesis mainly includes:Introduction to the research topic and literature review. Computation of intrinsic and extrinsic parameters by the process of mono and stereo camera calibration. Image pre-processing, stereo image rectification, feature point detection and extraction are also discussed. Gear chamfering angle measurement system is designed, experimentations are carried out to verify the accuracy of the system and compute the angle for chamfered gear edge. The error in the results is analysed and solution is also proposed for accuracy impreovement.